Zepro ZDK 250 135 User manual

ZEPRO
Tel.: [phone]
E-mail: [email protected] |zepro.com
78353TL
2022-06-03
Installation Instructions
Tail Lift
ZDK 250 135/155

ZDK 250 135/155Contents
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Contents
1 Important information ..................................................................................... 5
1.1 Attention! ................................................................................................ 5
1.2 Technical support.................................................................................... 5
1.3 Identication ........................................................................................... 6
1.4 CE marking............................................................................................. 6
1.5 Product approval ................................................................................... 6
1.6 Hydraulic oil ............................................................................................ 6
1.7 Guarantee............................................................................................... 6
1.8 Repainting .............................................................................................. 7
1.9 Battery maintenance............................................................................... 7
2 Safety rules ....................................................................................................... 8
2.1 Moving parts - free movement................................................................ 8
2.2 Connection of third-party equipment is forbidden................................... 8
2.3 Installation .............................................................................................. 8
3 Before installation ............................................................................................ 9
3.1 Vehicle chassis requirements................................................................. 9
3.2 Statutory dimensions .............................................................................. 9
3.3 Calculating the installed dimensions .................................................... 11
3.4 Rear member cut-outs.......................................................................... 14
3.5 Prepare the tail lift................................................................................. 15
3.6 Temporary connection .......................................................................... 17
4 Installation ..................................................................................................... 20
4.1 Platform ................................................................................................ 23
4.2 Armstops .............................................................................................. 28
4.3 Sealing strip (horizontal)....................................................................... 29
4.4 Sealing strip (vertical) ........................................................................... 29
4.5 Purging the cylinders ............................................................................ 31
4.6 Angle sensor / Inclinometer.................................................................. 32
4.7 Controllers ............................................................................................ 34
5 Cable routing ................................................................................................. 36
5.1 General................................................................................................. 36
5.2 Sizing electrical systems ...................................................................... 37
5.3 Main power cable, earth cable, main fuse and main switch ................. 38
5.4 Control power cable.............................................................................. 40
5.5 Open platform alarm............................................................................. 40
5.6 Foot controller / Warning lights............................................................. 40
6 Connection...................................................................................................... 41
6.1 Cable grommet ..................................................................................... 41
6.2 Connection ........................................................................................... 42
7 Powering up the tail lift.................................................................................. 50

ZDK 250 135/155
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Contents
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8 Electrical and hydraulic diagrams ................................................................ 51
8.1 ZDK 250 MA (TLC-B1) ......................................................................... 51
8.2 ZDK 250 MA (ZePRO1)........................................................................ 52
8.3 ZDK 250 MA with electric autotilt, Angle sensor IFM (TLC-B1)............ 53
8.4 ZDK 250 MA with electric autotilt, Inclinometer (ZePRO1)................... 54
8.5 ZDK 250 MA with electric autotilt, Angle sensor IFM (ZePRO1) .......... 55
8.6 ZDK 250 DA (ZePRO1) ........................................................................ 56
9 Lubrication and oil level check ..................................................................... 57
9.1 Lubrication ............................................................................................ 57
9.2 Oil level check ...................................................................................... 57
10 Marking............................................................................................................ 58
10.1 Loading diagram................................................................................... 59
10.2 Identicationplate................................................................................ 60
10.3 Work area ............................................................................................ 60
10.4 Warning tape ....................................................................................... 60
10.5 Controller sticker................................................................................... 61
10.6 Danger area ......................................................................................... 62
10.7 Warningags....................................................................................... 62
11 Testing and verification ................................................................................. 63
11.1 Static load test ...................................................................................... 63
11.2 Dynamic load test. ................................................................................ 64
11.3 Test of safety functions......................................................................... 64
12 Registration .................................................................................................... 65
13 Specifications ................................................................................................ 65
13.1 Weights ................................................................................................ 65

ZDK 250 135/155Important information
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1 Important information
1.1 Attention!
The following warning signs appear in the installation instructions and are intended to draw your attention to cir-
cumstances that can potentially cause problems, near misses, personal injury and/or damage to the product, etc.
mWARNING!
WARNING indicates a potential hazard, which if ignored may lead to serious, life-threatening injury.
mCAUTION!
CAUTION indicates a potential hazard, which if ignored, may lead to minor injuries.
IMPORTANT!
IMPORTANT indicates a risk of equipment damage.
NOTE!
NOTE refers to additional information that may help the reader understand, or perform, a given operation.
1.2 Technical support
If technical support is needed, please contact ZEPRO. Tel: [phone], E-mail: [email protected].
Always be ready to state the tail lift’s production number to guarantee you receive the correct information. The
productionnumberisgivenontheidenticationplatelocatedonthetailliftframe.
Image 1. Identification plate

ZDK 250 135/155
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Important information
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1.3 Identication
E.g. ZDK 250 - 135 MA
_ _ _ _ _ _ - _ _ _ _ _
ZDK = Standard model
Max. lifting capacity x 10 (kg)
Max. lifting height - 135 = 1340 mm
- 155 = 1530 mm
Cylinder model, MA = Double acting Adjustable Tilt
Single acting Single speed Lift
DA = Double acting Adjustable Tilt
Double acting Single speed Lift
1.4 CE marking
ZEPRO tail lifts for sale on the European market are CE marked (Conformité Européenne). The manufacturer
guarantees that the product complies with the EU Machinery Directive.
Followtheinstallationinstructionscarefully.Modicationsnotapprovedinwritingbythemanufacturerarenot
permitted. Welding is not permitted.
1.5 Product approval
Properly assembled, this product meets relevant requirements according to EN 1756-1:2001 + A1:2008.
1.6 Hydraulic oil
If the hydraulic oil needs to be replenished, only the oil recommended by ZEPRO is permitted to be used.
Hydraulicsystemswithhydraulicoiltankswithoutlabellingareonlypermittedtobelledwithhighlyrened
mineral oil (art. no. 21963, 1 litre).
Hydraulicsystemswithhydraulicoiltanksmarkedwithaspecicationforthehydraulicoilareonlypermitted
tobelledwiththeoilspeciedonthelabel.
1.7 Guarantee
The ZEPRO warranty applies only if assembly has been carried out according to ZEPRO's assembly instruc-
tions by a ZEPRO approved bodybuilder.
Afterinstallation,testingandverication,registerthetaillift’sdeliverycardtovalidatethewarranty.

ZDK 250 135/155Important information
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1.8 Repainting
Image 2. Piston rods, cyl-
inder covers and boots
Image 3. Hydraulic hoses Image 4. Cables
1.9 Battery maintenance
When storing for longer than 1 week, it is recommended to disconnect the lift from the battery via the main
switch or by releasing the lift’s main fuse, in order to reduce the risk of the battery discharging. The length of
time the vehicle can be stored without the battery charge level becoming too low depends on the condition of
the battery, the charge level prior to storage and how much power other components in the vehicle take from
the battery. After a period of storage, the battery must always be charged fully before operating the lift.
When the lift is operated repeatedly without starting or using the vehicle during lift installation or carrying out
service and repairs, use the battery charger between operations to maintain battery charge .
IMPORTANT!
The battery charger must be disconnected when operating the lift. Risk of material damage.
IMPORTANT!
Piston rods and cylinder covers must not be painted. Among other things, this can damage the cylinder gaskets.
Boots, hydraulic hoses and cables may not be coated/painted as the solvent in the paint can damage the hoses and cables and
impair durability.

ZDK 250 135/155
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Safety rules
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2 Safety rules
2.1 Moving parts - free movement
min. 40 mm
10º
10º
Image 5. Clearance to the closest part of
the cylinder must be at least 40 mm
Image 6. The platform may not be tilted
down more than 10º from the horizontal
2.2 Connection of third-party equipment is forbidden
mWARNING!
Connecting third-party equipment (electric or hydraulic) to Zepro tail lifts is forbidden. Connecting third-party equipment could
interfere with the lift’s system and its safety functions. Risk of injury and damage. If it is necessary to install other equipment,
check the vehicle manufacturer’s body instructions and use the attachment features on the vehicle.
2.3 Installation
mWARNING!
Installation where the platform cannot reach ground level is prohibited.
mWARNING!
ZEPRO tail lifts are only approved for installation using ZEPRO assembly kits.
IMPORTANT!
All specied tightening torques apply when using torque wrench or screw/nut runner with torque control. Torque spread max ±5%.
mWARNING!
During nal inspection*, the space occupied by the moving
cylinders must be cleared and made safe. There is a risk
of collision between the cylinder and the following items:
subframe, truck chassis, beam for rear light (number
plate) and the chassis bracket of the lift (with a short
overhang).
**Final inspection to be carried out with the platform at
the vehicle oor and tilted down 10°. The clearance from
the closest part of the cylinder must be at least 40 mm.
mWARNING!
The platform may not be tilted down more than 10º from
the horizontal.

ZDK 250 135/155Before installation
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Max. 450 mm.
(Air suspension)
Max. 500 mm.
(Conventional suspension)
Max 300 mm.
8º
Image 7. Cross section of vehi-
cle chassis frame beam
70
70
220
4
R6(x2)
X
Y
3 Before installation
3.1 Vehicle chassis requirements
In order to comply with the applicable underrun
protection standards, there are requirements for the
vehicle chassis on which the rear tail lift is mounted.
The moment of inertia in a cross-section on the current
frame beam (excluding any support frame) shall not be
less than 937 cm4. Thus the frame beam cross-section
must measure at least 220x70x4 mm, which cor-
responds to a minimum moment of inertia of 937cm4
around the x-axis. See Image 7. If in doubt, contact
ZEPRO for support.
3.2 Statutory dimensions
Distance between the beam and the ground when the vehicle is unloaded:
• Max. 450 mm for vehicles with air suspension.
• Max. 500 mm for vehicles with conventional suspension.
If the exit angle with the above setting is less than 8º, the distance between beam and ground in an unladen
vehicle may be increased until the angle is 8º, but to max 550 mm.
Horizontal distance from the outermost part of the platform to the underrun protection: Max 300 mm.
See Image 8.
NOTE!
The underrun protection must be located further back and lower.
Image 8. Statutory dimensions
mWARNING!
The above dimensions are the minimum permitted for
the installation of underrun protection. The strength
requirements for mounting the tail lift usually require
larger dimensions.

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Before installation
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0-100 mm.
Horizontal distance from the outer edge of the member
to the outside of the wheel: Max. 100 mm.
See Image 9.
The lateral distance between the underrun protection
and the moving parts of the tail lift must not exceed
25 mm. See Image 10.
Each of the individual parts of the underrun protec-
tion must have a surface area of at least 350 cm2.
See Image 10.
Image 9. Statutory dimensions
Image 10. Statutory dimensions
Max 25 mmMax 25 mm
Min. Area: 350 cm2